No-stir dry mix with pudding granules for cake with discontinuous pudding phase

ABSTRACT

Disclosed are dry mixes for cakes, especially layer type, for the provision of finished cakes having a discontinuous pudding phase. The present dry mixes require no batter mixing or aeration but merely require the addition of measured amounts of water and baking. The present mixes comprise a cake component comprising a conventional full formulation dry mix for cakes in a particular physical form referred to as &#34;granulated.&#34; Additionally, the mixes comprise a pudding component comprising a granulated form. The granules of both the cake and pudding components are each essentially characterized by the physical features of (1) particle size, (2) bulk porosity, (3) density, (4) initial rates of moisture absorption, and (5) moisture content. For the layer cake component the particle size of the layer cake granules essentially ranges from about 0.9 to 3.0 mm. The bulk porosity essentially ranges from about 0.55 to 0.64. The density essentially ranges from about 0.45 to 0.70 g./cc. The rates of initial moisture absorption essentially range (at 70° F.) from about 0.055 to 0.075 gram of water per gram of mix per second. The moisture content is less than about 5%. For the pudding component, the particle size essentially ranges from about 2.8 to 3.4 mm; the bulk porosity ranges from about 0.50 to 0.65; the density ranges from about 0.5 to 0.7 g./cc; the initial rate of moisture absorption from about 0.060 to 0.080 g. H 2  O/g. mix-sec., and a moisture content of less than about 5%. Conventional agglomeration equipment and techniques employing moisture as the binding agent are useful herein for preparing the granulations of the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to food products. More particularly, thepresent invention relates to dry culinary mixes for the provision oflayer cakes, to finished cakes prepared from such mixes and to methodsof preparing such finished cakes.

2. The Prior Art

The use of prepared mixes has received wide usage, particularly in homebaking. These dry mixes provide convenience by eliminating the steps ofingredient selection, measurement and blending. To prepare cake battersfrom these dry mixes for baking, liquid materials such as water or milk,liquid shortening, eggs, etc. are added and the combination is thenmixed to form a homogeneous mixture or batter and beaten to incorporateair. The resulting aerated batter is then typically transferred to agreased pan or tray and then baked to obtain finished cakes.

While these dry culinary mixes are convenient, it is apparent from theabove description that the typical cake preparation procedure stillcontains several steps. It would be desirable then to eliminate one ormore of these steps to provide products of even greater convenience. Tothis end, certain products have been marketed from time to time whichattempt to provide greater convenience to the user. For example, onesuch product comprises previously hydrated batter. While somewhat moreconvenient, such products suffer from several disadvantages by virtue ofthe presence of water, e.g., limited shelf life, special storagerequirements, such as refrigeration, etc. These disadvantages haveprevented these products from obtaining widespread acceptance.Accordingly, most art efforts then have been directed toward providingdry mixes for cakes and to improving both the use or characteristics ofthe dry mix or of the finished cake prepared therefrom. Dry mixes forcakes may be divided into two groups, namely shortening-type mixes,e.g., layer cakes and non-shortening type mixes, e.g., angel food cakes.The present invention relates to both types, generally, and inparticular to shortening-type cake mixes. Shortening-type cake mixescontain, as major ingredients, flour, sugar, and shortening. To thesemajor constituents other ingredients such as emulsifier, (generallyincorporated into the shortening) starches, flavors, leavening, eggsolids, non-fat milk solids may be added.

Greater convenience in using dry mixes can be provided by "fullformulation" cake mixes. Full formulation mixes are distinguished frompartial formulation mixes in that only water need be added for mixingand beating to form an aerated batter. Such full formulation mixes arecommercially available and enjoy widespread acceptance particularly inthe food service or commercial food industry.

Full formulation cake mixes, while convenient as regards time of mixing,nevertheless require the addition of prescribed quantities of water,blending at low speed to form a batter and subsequent aeration andtransference to a greased baking container. Even greater convenience forthe at-home preparation of layer cakes are provided by the"stir-in-the-pan" layer cake dry mixes. Typically, these are fullformulation cake mixes which are specially formulated to be rapidlyrehydratable and to be hand mixable. (See, for example, U.S. Pat. No.3,694,229, issued Sept. 26, 1972 to N. Norbsy et al.) Certain cake mixesof this type contain agglomerated all-purpose wheat flour as a componentto aid in the rapid hydration of the cake mix. (See, for example, U.S.Pat. No. 3,708,309, issued Jan. 2, 1973 to G. E. Johnson et al.) each ofwhich are incorporated herein by reference. However, even these mixesmust still be hand stirred to form a batter. Moreover, these cake mixesare typically marketed in combination with specially coated containersso that batters can be prepared in the baking pan and thereafter bakedwithout the cake sticking to the pan.

Co-pending application (Ser. No. 409,204, filed Aug. 18, 1982 by J. R.Blake, R. K. Knutson and G. J. VanHulle) entitled "No-Stir Dry Mixes forLayer Cakes," and which is incorporated herein by reference, provides animprovement in full formulation culinary mixes. The improvement residesin providing full formulation cake mixes in a particular physical form,i.e., granules, which allow for the preparation of finished baked cakeswithout requiring the conventional steps of mixing to form a batter,aerating the batter, greasing or coating the baking container ortransferring the aerated batter to the coated baking container.

The present invention provides a further improvement to the novel layercake granules of this co-pending application. The present inventionprovides dry mixes for layer cakes in the form of granules additionallycomprising a pudding component. It has been surprisingly discovered thatdry pudding compositions can also be prepared in the novel particularphysical form of granules and that such granules can be combined withgranulated layer cakes to be used for the preparation of a novel form ofa finished cake. The present dry mixes allow for a new form of finishedcakes having a discontinuous and distinct phase of pudding. Such drymixes of the present invention additionally provide the convenienceadvantages of no mixing, aeration, etc.

Dry mixes for layer cakes are known which are characterized ascontaining pudding. Generally these mixes contain conventional layercake formulations in terms of ingredients and their concentrations.These mixes additionally contain those ingredients which typicallycomprise either conventional or instant pudding dry mixes, namely,sugar(s), flavorings and ungelatinized starch or pregelatinized starch.As a rule, these extra ingredients, or extra levels of ingredients(e.g., sugar) are, however, typically uniformly blended with the otherlayer cake ingredients. Together, the mix ingredients are formed into ahomogeneous batter with added liquids in conventional manner, aerated,baked, etc. to form finished layer cakes. These cakes are characterized,thus by having a homogeneous structure. The extra pudding ingredientsmodify the finished cake to provide enhanced moistness and possibly aheavier texture rather than the lighter, drier, more crumbly texture oftraditional layer cakes. In contrast, the present finished cakes containdiscrete, distinct, or discontinuous regions of pudding more analogousto cream-filled cake desserts.

Of course, agglomeration is an old technique in the food art and avariety of food products are available in agglomerated form.Additionally, the food art is replete with agglomeration techniques.(See, for example, "Agglomeration Processes in Food Manufacture," byNicholas Pintauro Noyes Data Corporation, 1972.) Generally, foodproducts are agglomerated to improve one or more of several productattributes. First, food products have been agglomerated to improveaesthetics. For example, soluble coffee powders have been agglomeratedprimarily for product aesthetics. (See for example, U.S. Pat. No.3,135,612 issued June 2, 1964 to E. R. Hair). Second, agglomeration hasbeen more commonly used to provide products of improved materialhandling, e.g., pourability. Exemplary agglomerated products and methodsinclude those described in U.S. Pat. No. 4,073,951, issued Feb. 14, 1978to R. G. Sargeant. Most commonly, very large numbers of food productshave been agglomerated in the past to enhance their solubility ordispersion characteristics in liquids. These products include flour,non-fat dry milk solids, cocoa, sugars, eggs, etc.

Exemplary products and methods of preparation are disclosed in U.S. Pat.No. 4,156,020, issued May 5, 1979 to Bohrmann et al.; U.S. Pat. No.4,021,582, issued May 3, 1977 to Bohrmann et al.; U.S. Pat. No.4,016,337 issued April 5, 1977 to J. Y. Hsu.

While these agglomerated products and methods have been used in the pastfor the provides of products exhibiting improved aesthetics, materialhandling and dispersability in liquids, it has been surprisinglydiscovered that agglomeration can be employed to provide puddingmaterials useful as ingredients in no-stir layer cake mixes and to novelforms of finished cakes prepared therefrom. Additionally, the presentgranules for both layer cake and pudding components are much larger insize than those of other typically agglomerated food products. Moreover,while general agglomeration techniques have been used to realize thepresent granules, the granules are importantly characterized by specificphysical properties not previously recognized as important to cake mixformulation.

SUMMARY OF THE INVENTION

The present invention relates to dry mixes for layer cakes which can beused to obtain finished cakes having a discontinuous pudding phase. Thedry mixes comprise a layer cake component or fraction and a puddingcomponent or fraction each of which are in a particular physical formreferred to herein as "granulated." Most surprisingly, the presentinvention provides mixes from which cakes can be conventionally bakedbut which do not require mixing to form a batter, or batter aeration, orcoating the baking container, and/or without transferring the aeratedbatter to the baking container.

The granules of both the layer cake component and the pudding componentare essentially characterized by the physical features of (1) particlesize, (2) bulk porosity (total void volume/total volume), (3) density,(4) initial rates of moisture absorption, and (5) moisture content.

The particle size of the present layer cake component granulesessentially ranges from about 0.9 to 3.0 mm. The bulk porosityessentially ranges from about 0.55 to 0.64. The density essentiallyranges from about 0.45 to 0.70 g./cc. The rates of initial moistureabsorption essentially range (at 70° F., 21° C.) from about 0.055 to0.075 gram of water per gram of mix per second (g./g.s.). The moisturecontent is desirably less than about 5% by weight.

The particle size of the present pudding fraction granules essentiallyranges from about 2.8 to 3.35 mm. The bulk porosity essentially rangesfrom about 0.05 to 0.65. The density essentially ranges from about 0.5to 0.7 g./cc. The rates of initial moisture absorption essentially range(at 70° F., 21° C.) from about 0.060 to 0.080 gram of water per gram ofmix per second (g./g.s.). The moisture content is desirably less thanabout 5% by weight.

Additionally, the present invention relates to a novel form of finishedcake having a discontinuous pudding phase. In its method aspect, thepresent invention embraces novel methods for preparing such finishedcakes.

DETAILED DESCRIPTION OF THE INVENTION

The improved dry mixes for layer cakes of the present invention can beused to provide novel finished layer cakes having a discontinuouspudding phase. Additionally, the improvement resides in part in theelimination of several previously-recognized-as-essential steps offinished cake preparation: namely, batter mixing, batter aeration andcontainer greasing. The improved cake mixes comprise a layer cakefraction and a pudding fraction each of which are novel in physical form(referred to herein as "granules"). Granules of both the layer cakefraction and the pudding fraction are each characterized by (1) particlesize, (2) bulk porosity, (3) density, (4) moisture content, and (5)initial rates of moisture absorption. Each of these physical attributesas well as cake formulation, method of granule preparation, andcomposition use are described in detail below.

Throughout the specification and claims, percentages and ratios are byweight and temperature in degrees Fahrenheit, unless otherwiseindicated.

A. Layer Cake Fraction

A cake fraction is the principal component of the present dry mixes.Highly preferred for use herein as the cake fraction is a layer cake.The present cake fraction can be supplied by conventional fullformulation cake compositions. Full formulation cake mixes are wellknown in the art and such conventional full formulation is useful hereinfor fabrication into the present granules. The art is replete withcompositions suitable for use such as are described in U.S. Pat. Nos.3,708,309 and 3,694,229 referenced above for layer cakes. Additionalsuitable layer cake formulation are given in U.S. Pat. No. 3,135,612,issued June 2, 1964 to E. R. Hair et al. Exemplary chiffon cakeformulations can be found in U.S. Pat. No. 3,713,845 (issued Jan. 30,1973 to Kuffel). Useful angel food cake mixes can be found in U.S. Pat.No. 3,653,917 (issued Apr. 4, 1972 to Wahba et al.) Each of thesereferences are incorporated herein by reference.

Generally, such full formulation dry layer cake mixes comprise:

about 35% to 45% flour;

about 30% to 60% sucrose;

about 1% to 16% shortening;

and from about 0.3% to 10% chemical leavening agent.

The shortening component generally includes about 1% to 5% of emulsifierbased on the weight of the shortening component.

Optionally, other selected ingredients, e.g., non-fat dry milk solids oregg solids, vitamins, flavors, color, starch, etc., can each comprise upto about 3% of the cake mix.

Since the present invention finds particular suitability for use inconnection with layer cakes, the following description of the presentinvention generally refers to layer cakes. However, it is to beappreciated that as indicated above, the present invention contemplatesother cake types as well.

1. Particle Size

As indicated above, the physical structure of the dry layer cakes of thepresent invention are distinct from the physical structure of cake mixesof the prior art. Importantly, the present cake mixes are provided inthe form of a granule essentially characterized in part by particlesize. The present cake granules essentially range from about 0.9 to 2.8mm. in shortest dimension. Cake fraction granules within this desiredsize range can be supplied by granules having the following sieve screenanalysis.

    ______________________________________                                        Weight %          U.S. Standard Size                                          ______________________________________                                        100%              Through No. 6                                                0%               Through No. 20                                              ______________________________________                                    

Oversized granules are to be generally avoided since great difficultiesexist in ensuring complete hydration of oversized granules. Deficienthydration of granules can undesirably result in finished cakes havinghard spot defects. Conversely, undersized granules are also to begenerally avoided since difficulties can arise in uneven absorption ofmoisture due to the higher surface area of the smaller cake fractiongranules. Differences in moisture absorption can lead to absence of cakephase homogeneity.

Better results in terms of granule rehydration are obtained when thegranules range in shortest diameter from about 1.4 to 2.0 mm. Cakefraction granules within this preferred size range can be supplied bygranules having the following sieve screen analysis.

    ______________________________________                                        Weight            U.S. Standard Size                                          ______________________________________                                        100%              Through No. 10                                              100%              On No. 14                                                   ______________________________________                                    

While particle size is an important physical feature of the presentgranules, it is the combination of physical features of the presentgranules which are important to their usefulness herein.

2. Bulk Porosity

Another essentially important physical feature characterizing thepresent cake mix in granule form is "bulk porosity," or "void space,"i.e., the total void volume/total volume of the granulated cake mix. Itis intended that the consumer will pour a package of the present cakemix in granule form to an ungreased baking container. Thereafter, ameasured amount of liquid, typically water, will be added directly tothe pan, and then baked immediately thereafter. For proper rehydrationand in situ batter formation during the early part of the baking cycle,it is important then that the volume of liquid added be approximatelyequal to the total void volume of the granulated mix.

Undesirable effects can result when either the volume of liquid to beadded exceeds or fails to equal the total void volume. If in excess, atop or overlayer of water will lie over the top surface of the granules.The granules may fail to completely hydrate during the baking cycle andform defects in the finished cake. Additionally, the specific volume ofthe finished cake may be undesirably decreased. If the volume of liquidaddition is deficient, then the top layer of granules above the levelreached by the added liquid may fail to rehydrate at all resulting in acharred top crust in the baked product.

Selection of specific bulk porosities will be influenced primarily bythe desired weight percent of moisture desired to be added. Thus, forexample, for a specific culinary mix formation, it may be desirable toadd sufficient water such that the combination prior to baking has amoisture content of 40% by weight. If such a mix is fabricated intogranules according to the present invention having a bulk porosity of0.50, having a density of 0.65, and a bulk porosity of 0.5, then 100 ml.of granules would weigh 65 g., and contain 50 ml. of void space. For adesired moisture content of 40%, about 43 ml. of water would need to beadded to the granules and would approximately equal the total availablevoid space. While not exact, this correlation is best with lower bulkporosities and higher densities. Generally, less water is added thanwhat is theoretically required to fill the avialable void space asmeasured by the method described below. While not wishing to be bound bythe proposed theory, the disparities are believed due to the surfacetension of water which prevents it from quickly occupying the smallervoid regions of high porosity and low density granules.

Of course, the bulk porosity will be influenced not only by the size butalso the shape of the granules. While in the preferred embodiments ofthe present invention the present granules are spherical in shape, thepresent invention embraces other shapes both irregular and regularshapes, e.g., oval or ellipsoid.

A determination of bulk porosity as defined above is made as follows:

1. 100 Grams of granules are poured into a 100 ml. graduated glasscylinder. The volume it occupies =V., e.g., 25 ml.

2. 60 Milliliters of carbon tetrachloride are poured over the granulesin the cylinder and allowed to stand until air bubbles no longer rise tothe surface. The total volume of carbon tetrachloride and submergedgranules equals V₂, e.g., 67 ml.

3. Bulk porosity is then calculated from these data, thus: ##EQU1##

The granules of the present invention desirably range in bulk porosityfrom about 0.55 to 0.64. Better results in terms of hydration control,i.e., avoiding a surplus or deficiency of moisture are obtained when thebulk porosity ranges from about 0.58 to 0.62.

3. Density

Another important physical feature of the present granulated cake mixesis their density. Density control is important to realization ofgranules of the present invention exhibiting desirable rates of moistureabsorption. Granules useful herein have a density essentially rangingfrom about 0.45 g./cc. to 0.70 g./cc. Better results in terms of desiredhydration and water filling of the granule bed are obtained when thedensity ranges from about 0.50 to 0.60 g./cc.

4. Moisture Content

The moisture content is also an important feature of the presentgranules. The moisture content strongly affects the initial rate ofmoisture absorption as well as other features of the agglomerates. It isessential that the moisture content be less than about 5%. Betterresults in terms of finished cake grain texture and specific volume areobtained when the moisutre content of the present granules is less thanabout 4%. For best results, a moisture content of less than about 3% isdesirable.

5. Initial Rate of Moisture Absorption

Still another important physical feature of the present granules is theinitial rate of moisture absorption. The term "rate of moistureabsorption" is defined as the speed at which the granules absorb water.Should this rate be too fast, the particles first contacted by thereconstituting liquid will absorb a disproportionate quantity of waterresulting in an uneven distribution of water. Should the rate be tooslow, the particles will not attain the desired degree of rehydrationwithin the baking cycle and as a result, the finished cake will be asuccession of watery areas, which were originally the voids, and heavyareas, with dry centers, which were originally the location of the drygranules. Ideally, the rate of absorption should be such that therehydrating liquid will flow into all of the void areas in theconsolidated mass before substantial swelling occurs during release ofCO₂ from the leavening, each of which are dependent upon the temperatureincrease occuring during the baking cycle.

Although it is intended that the reconstituting liquid be addedpractically instantaneously, when the moisture absorption rate issubstantially above 0.075 g./g.s., the water cannot be readilyintroduced at a rate fast enough to prevent non-uniform rehydration.Preferably the granules have an initial absorption rate in the range of0.055 to 0.060 grams of water per gram of product per second.

The determination of granule's initial moisture absorption rate wasaccomplished as follows. To 5 gram increments of dry granules in ashallow pan, was added an excess of water, i.e., 25 ml. of water. Testsare conducted with water temperatures of about 70° F. After about 10seconds, the excess water was poured off and measured. The total amountof water absorbed was corrected for the time interval and quantity ofgranules, and reduced to grams of water absorbed per gram of product persecond ("g./g.s.").

B. "Pudding" Component

The present dry mixes for layer cakes additionally comprise as anessential ingredient a pudding component in a particular physical form.The term "pudding" is used in its conventional sense in the food art torefer to sweetened soft food systems typically based upon starch as thegelling or viscosity building ingredient. The pudding componentcomposition is an important feature of the present composition. Usefulherein are those dry pudding compositions containing a cold waterdispersible, i.e., pregelatinized starch. These dry mix puddingcompositions are commonly referred to as "instant puddings". The art isreplete with such compositions and the skilled artisan will have noproblem with selecting suitable compositions for use herein. (See, forexample, U.S. Pat. No. 3,332,785, issued July 25, 1967 to E. Kuchinke etal., U.S. Pat. No. 2,897,086, issued July 28, 1959 to E. A. Sowell etal., U.S. Pat. No. 2,927,861, issued Mar. 8, 1960 to H. J. Charie, andU.S. Pat. No. 3,914,456, issued Oct. 21, 1975 to Norsby et al.).Compositions requiring cooking for starch gelatinization are, however,not useful herein as the pudding component.

Typically, such instant pudding compositions comprise sugar, flavoring,and coloring agents, and either the combination of pregelatinized starchand setting agents, e.g., calcium or phosphate salts, or modifiedpregelatinized starch or combination of starches as the gelling agent.Numerous other optional ingredients for texture or other productproperty modification can be included, e.g., emulsifiers fordispersibility, soy protein for fortification, etc.

While conventional instant puddings can be used herein, the finishedcakes realized therefrom can have pudding regions wherein the pudding ishard, i.e., firmly gelled, rather than the preferred, smooth and creamytexture realized from mixes having the preferred pudding fractionformulation.

In the most preferred embodiment, the pudding component essentiallycomprises from about 4% to 9% of a waxy maize pregelatinized starch,from about 60% to 85% sugar(s), from about 0.25% to 1.0% cold watersoluble gum, and from about 0.005% to 0.015% of alpha-amylase.Preferably, the pudding component comprises from about 6 to 8% starch,from about 65 to 75% sugars, from about 0.5 to 0.75% gum(s) and about0.01% alpha-amylase. Such a pudding fraction formulation is especiallysuited to the provision of finished cakes having the highly preferredpudding regions of smooth and creamy texture. Other optional components,for example, non-fat dry milk solids, flavors, colors, etc. can bepresent from about 0.5% to 30% of the pudding fraction.

Pregelatinized starch is a widely used material. Various starches areavailable from numerous commercial sources originating from a variety ofstarch sources including tapioca, waxy maize, corn and the like.

Suitable sugars can include conventional mono- and disaccharide sugarssuch as sucrose, dextrose, lactose, fructose, corn syrup solids andmixtures thereof.

Suitable cold water soluble gums include sodium and propylene glycolalginates, guar gum, locust bean gum, kappa carrageenan, gum Arabic,pectin, methylcellulose, hydroxypropyl methylcellulose and mixturesthereof. Preferred gums are selected from the group consisting of guargum, locust bean gum and mixtures thereof.

Amylases are the enzymes which hydrolyze starch into reducingfermentable sugars, mainly maltose and dextrins. The amylases areclassified as saccharifying (beta-amylase and dextrinizing(alpha-amylase). Both enzymes are specific for alpha-glucosidic bondswhich connect monosaccharide units into the large polysaccharides. Bothalpha and beta amylases are widely available commercially and areproduced from a variety of sources including malting of grains,production of fungi and bacteria and from pancreatin, primarily frompigs. U.S. suppliers include Novo Industri A/S, Enzymes Division,Bagsvaerd, Denmark, Miles Laboratories, Inc., and WorthingtonDiagnostics (Div. of Millipore Corp.).

The amount of the pudding fraction is not critical but depends on thedesired level of pudding in the finished cake. Good results are obtainedwhen the pudding fraction ranges from about 10% to 30% of the dry mix.Preferably, the pudding fraction comprises from about 20% to 25% of thedry mix.

Of course, the present invention contemplates employing more than onepudding component granule in the present mixes. Thus, for example,multiple flavors and/or colors of pudding granules can be used in asingle cake. Some variations in size of the granules is also possible.

1. Particle Size

Particle size is a critical feature of the present pudding fractiongranules. The present pudding granules essentially range from about 2.8to 3.4 mm. in shortest dimension. Pudding granules within this desiredsize range can be supplied by pudding granules having the followingsieve screen analysis:

    ______________________________________                                        Weight %          U.S. Standard Sieve                                         ______________________________________                                        100%              Through No. 6                                               100%              On No. 7                                                    ______________________________________                                    

Oversized granules are to be strictly avoided since great difficultiesexist in ensuring complete hydration of larger granules. Deficienthydration of granules can undesirably result in finished cakes havinghard spot defects. Conversely, undersized granules are undesirable sinceloss of the pudding regions as distinct entities can occur as well asundesirable modification of the texture and other attributes of theproximate layer cake regions.

2. Bulk Porosity

The bulk porosity of the pudding fraction granules is also an importantfeature and desirably ranges from about 0.50 to 0.70. Better results interms of proper granule rehydration are obtained when the bulk porosityranges from about 0.50 to 0.60. For best results, the bulk porosity isabout 0.55 to 0.60.

3. Density

Desirably, the density of the pudding granules ranges from about 0.5 to0.7. Better results in terms of granule hydration are obtained when thedensity ranges from about 0.5 to 0.65. For best results, the densityshould be about 0.55 to 0.60.

4. Moisture Content

The moisture content is an important feature of the pudding fractiongranules for the same reasons as for the layer cake fraction granules.Desirably, the moisture content is then less than about 5%. Betterresults in terms of granule hydration are obtained when the moisturecontent has been reduced to less than about 4%. For best results, themoisture content should be less than about 3%.

5. Initial Rate of Moisture Absorption

The initial rate of moisture absorption is similarly important to thepudding fraction granules for reasons similar to that for the layer cakefraction granules. Desirably, the rate is at least about 0.060 to 0.075g./g.s. Better results in terms of rehydration characteristics areobtained when the initial rate is at least about 0.065 to about 0.075g./g.s..

C. Adjuvants

The present dry mixes can optionally contain a variety of additionalingredients suitable for rendering finished cakes prepared therefrommore organoleptically desirable. Such optional dry mix componentsinclude flavoring nuts, fruit pieces, preservatives, vitamins and thelike. If present, such optional components comprise from about 1% to 10%of the dry mixes of the present invention.

It is an unexpected advantage of the present invention that superiorityin supporting such layer cake adjuvants is provided. Since a batter isformed only for a brief period during the baking cycle, less support forthese materials is needed. Also, greater control over placement of suchmaterials is possible since mixing can be eliminated. Relatively greaterquantities of adjuvants can be added without fear of overloading thecake structure or settling of the added materials.

METHOD OF PREPARATION

The present granules for both the layer cake and pudding fractions caneach be prepared using conventional agglomeration apparatus andtechniques. The art is replete with suitable methods and equipment.Preferred for use herein are those employing moisture as the bindingagent. In particular, it has been found that a disc pelletizer such asModel 036 VD Stainless Steel, manufactured by Ferro-Tech, Wyandotte, MI,is especially suitable for use herein. Another apparatus useful hereinis a Schugi Flexomix 160 (manufactured by Schugi B. V., Amsterdam,Netherlands). An advantage of employing a disc pelletizer lies in thetight control over the particle size of the granules compared to otheragglomeration apparatus techniques. Such an advantage is especiallyimportant in providing the extra large granules of the presentinvention.

The particular physical properties of the granules are adjusted in knownmanner by control of the operating conditions of the particularagglomerator. For the disc pelletizer, the incline of the bed, beddepth, RPM of the disc, the rate of water addition and amount of wateradded per unit weight of dry mix are each important operatingparameters. Other minor operating conditions include the position of theplow as well as the location of the dry feed addition and the waterspray. Particle size is controlled primarily by the discharge screeningof the pelletizer. However, yields of desirably sized granules areinfluenced by operating conditions.

Generally, bulk porosity is controlled by the extent of granule surfaceirregularity. Greater irregularity increases porosity. Using the discpelletizer, increases in bulk porosity are obtained with steeper bedangle, shallower bed depth, faster RPM's, higher rates of water additionand lower unit water additions.

Similarly, higher densities are obtained with gentler bed angle, deeperbed depth, slower RPM's, lower rates of water addition and higher unitwater additions.

Initial rates of moisture addition are dependent upon final moisturecontent, by density and bulk porosity. Generally, higher rates areobtained with lower densities, higher bulk porosities, and lower finalmoisture contents.

In a typical manner of preparation, the ingredients for the fullformulation layer cake are blended together to form a homogenousmixture. Thereafter, the mixture is agglomerated at room temperatureusing water as the binding agent generally bringing the moisture contentup to about 8-14%. Typically, both the dry particulate cake mixture orpudding fraction composition, and the water are carefully metered intothe disc pelletizer and tumbled. The dry particulate material is carriedbeneath a spray of water so that tiny granules or seeds first form andthen increase in size as rotation of the disc is continued, with themoistened particles being tumbled and rolled on the disc until pelletsof the desired size are formed and discharged from the disc. Thus, theparticles on which water is sprayed develop surface stickiness andagglomerate together while moving through a certain angular distanceover the surface of the disc before falling back toward the lower rim ofthe disc. As rotation of the disc continues, the granules so formed riseto the surface of the particulate mix and overflow the rim when theyhave reached the desired size.

As is well known, the particle size of the granules as well as the otherphysical properties produced on a pelletizing disc is controlled by anumber of factors, including the angle and speed of the disc, theposition of the plows, the location of the dry feed addition and thewater spray, and the rate of water addition. The specific conditionswill vary with each dry mix formulation and can be readily establishedby routine experimentation. In accordance with the present invention,these factors are controlled to produce pellets having a particle sizesuch that the bulk of the pellets will pass through a 6 mesh screen andwill be retained on a 20 mesh screen, and will have a moisture contentof about 10%-20%. Typically, the disc is inclined at an angle of about45° and is rotated at a speed of about 15-25 RPM. The diameter of thedisc used is commonly on the order of about 3 feet to 6 feet or more.Thereafter, the granules formed are screened and over and undersizedgranules recycled.

After formation, the granules are desirably dehydrated in conventionalmanner, e.g., with tray drying or vibrating bed drying each with forcedhot air convection. The moisture content desirably is reduced to lessthan about 5%.

The pudding granules are made separately in a similar manner by blendingthe ingredients, agglomerating using moisture as the binding agent,classifying to obtain granules of desired particle size and dehydrating.

The two dry mix fractions so prepared can be blended together orpackaged separately for use in blending as described below.

COMPOSITION USE

The present granulated dry mixes prepared as described above areconveniently prepared into finished cakes by a simple "pour-and-bake"operation. The cake mix is poured into an ungreased container anddistributed evenly through the pan. Thereafter, a measured amount ofwater is added to the dry mix and is evenly distributed by gravityalone. The combination can then be, and preferably is, baked immediatelythereafter in any convention without prior mixing or aeration, forexample, for 25 to 40 minutes at 350° F. to 425° F. (175° C. to 320°C.).

During baking the granules rehydrate and form a batter in situ. Whilenot wishing to be bound by the proposed theory, it is speculated hereinthat elimination of greasing or otherwise providing the baking containerwith a non-stick coating results from the added water or other liquidforming the continuous phase and being in contact with the containerduring most of the baking cycle.

Of course, if desired, the consumer may ignore the advantages providedby the present cake mixes and use the mix in a conventional manner toprepare a conventional more moist, layer cake. The consumer could thenbeat the water and cake mix combination to form a batter and then toaerate the batter, transfer to a greased container and then bake asabove. The resultant finished baked layer cake, of course, would nothave a discontinuous pudding phase.

The present invention can be used to prepare finished cake productswhich either cannot be prepared by present cake preparation mixes andtechniques or those which can be prepared only with great difficulty.For example, swirl cakes comprising a first region of one flavor and/orcolor cake, e.g., white and a second region of second flavor and/orcolor cake, e.g., chocolate, can be readily prepared by employinggranules of two cake mixes. Since no stirring is required in the cakepreparation, and since the granules do not move appreciably duringhydration, complex patterns in finished cakes can be easily realized.For example, cakes can comprise alternating thin layer of white andchocolate whether vertically or horizontally oriented. Similarly, thepudding component can be employed with considerable freedom. Multiplepudding component flavors and colors can be used. Swirl or otherpatterns for the pudding component can also be realized.

The finished cakes prepared from the present dry mixes surprisingly arecharacterized by a discontinuous pudding phase. Generally, the finishedcakes contain small beads, e.g., between about 2.0 to 3.5 mm. indiameter, of pudding distributed as desired through a continuous layercake phase.

The following examples are offered to further illustrate but not tolimit the invention disclosed herein.

EXAMPLE I

A large batch of dry mix for a white layer cake in the form of granulesof the present invention having the following formulation is prepared asfollows:

    ______________________________________                                        Amount      Ingredient       Weight %                                         ______________________________________                                        A. Cake Mix Fraction                                                          789.00 lbs.     Sucrose (cake grind)                                                                           39.450                                       735.00          Flour            36.750                                       200.00          Shortening (plastic)                                                                           10.000                                       94.68           Dextrose         4.734                                        40.00           Shortening (solid)                                                                             2.000                                        40.00           Egg white solids 2.000                                        20.00           Egg yolk solids  1.000                                        20.00           Non-fat dry milk solids                                                                        1.000                                        37.00           Leavening        1.850                                        16.00           Salt             0.800                                        4.00            Vanilla powder   0.200                                        2.32            Color            0.116                                        2.00            Gum              0.100                                        2,000.00                                                                             lbs.                      100.000%                                     B. Pudding Fraction                                                           567.00 lbs.     Sucrose (microse sized)                                                                        56.700                                       105.10          Dextrose         10.510                                       181.20          Cocoa            18.120                                       71.40           Non-Fat Dry Milk Solids                                                                        7.140                                        70.20           Pregelatinized Starch.sup.1                                                                    7.020                                        5.00            Gum.sup.2        0.500                                        0.10            Enzyme.sup.3     0.010                                        1,000.00                                                                             lbs.                      100.000%                                     ______________________________________                                         .sup.1 A pregelatinized waxy maize starch available from National Starch      Co., No. 780018.                                                              .sup.2 A guarbased gum available from National Starch as Dycol/4500FF.        .sup.3 An alphaamylase available from Novo Industri as T60L.             

The dry ingredients of each fraction are separately weighed and blendedin a ribbon blender for five minutes. The heated (120° F.) shortening isthen added to the cake component with a piston pump. The cake componentmixture is then blended and delumped with a cake finisher.

Both the cake mix and pudding fractions are individually agglomerated ina similar manner. Each fraction is fed at a controlled rate of aboutthree lbs./mn. to a 3 ft. (apx. 0.915 m.) disc pelletizer using a screwconveyor (Acrison, Inc. Model 1057). The disc pelletizer (FerrotechModel 036) is operated at 17 RPM, a disc angle of 50° and a bed depth ofabout eight inches (203 mm.). Water is atomized onto the mix at a rateof 120 ml./min. About 85% of the granules so prepared range in size fromabout on No. 10 to on No. 14 U.S. Standard size mesh. The granules havea moisture content of about 9.5 to 12.5%. The granules are then dried ina forced hot air dryer at 110° F. to 120° F. (43° C. to 49° C.) forabout 4 hours until a moisture content of about 3-4% is achieved. Thegranules are then screened so that about 98% of the cake mix range insize of from about 1.4 to 2.0 mm. While about 98% of the puddingfraction range in size of from about 2.8 to 3.4 mm.

The layer cake fraction granules so prepared are additionallycharacterized by a bulk porosity of 0.55, a density of 0.60, and aninitial rate of moisture absorption of 0.060 g./g.s.

The pudding fraction granules so prepared are additionally characterizedby a bulk porosity of 0.57, a density of 0.62, and an initial rate ofmoisture absorption of about 0.64 g./g.s.

635 Grams comprising one part pudding granules and three parts cake mixgranules uniformly blended as prepared above are added to a 9 in. × 13in. × 2 in. (apx. 23 cm. × 33 cm. × 5 cm.) baking container. Then, 423g. of water are added to the container. The mixture is then bakedimmediately at 350° F. (177° C.) for 20 to 25 min. to form a finishedcake.

The layer cake so prepared is characterized by numerous discrete regionsof pudding randomly and uniformly dispersed throughout the cake.

EXAMPLE II

A small batch of dry mix chocolate layer cake in the form of granules ofthe present invention having the following formulation is prepared asfollows:

    ______________________________________                                        A. Cake Mix Fraction                                                          Amount                Ingredient                                              ______________________________________                                        383.90     g.         Sucrose.sup.1                                           343.00                Flour.sup.2                                             115.00                Shortening.sup.3                                        40.00                 Dextrose                                                25.00                 Pregelatinized starch                                   20.00                 Cocoa                                                   20.00                 Dried egg whites                                        12.50                 Dried egg yolk                                          10.00                 Sodium bicarbonate                                      8.00                  Salt                                                    11.50                 Flavor                                                  3.00                  Leavening acid                                          1.00                  Gum                                                     7.10                  Color                                                   1,000.00   g.                                                                 ______________________________________                                        B. Pudding Fraction                                                           Ingredient        Weight %                                                    ______________________________________                                        Sucrose           68.178%                                                     Dextrose          12.880                                                      Non-fat Dry Milk Solids                                                                         8.750                                                       Locust bean gum   0.610                                                       Pregelatinized starch                                                                           8.570                                                       Enzyme            0.012                                                       Vanilla flavor    1.000                                                                         100.000%                                                    ______________________________________                                         .sup.1 A mixture of granular sucrose and microfine sucrose of 50 microns      (90% through a U.S. Standard Sieve No. 270). The weight ratio of granular     sugar to microcrystalline sucrose is approximately 1:3.                       .sup.2 An allpurpose flour made from selected soft red winter wheats          having a protein content of 8 to 10% by weight.                               .sup.3 Having a Solid Fat Index of approximately 22-26% at 70° F.      and comprising about 10% by weight of the shortening of a food grade          emulsifier comprising a mixture of mono and polyglycerol monoesters of        stearic and palmatic acid marketed by Durkee Foods.                      

About 1,000 g. of the ingredients of each fraction are separatelyweighed and the dry ingredients blended together in a mixing bowl. Theshortening is added to the cake mix fraction slowly with low speedmixing until only about 25% of the mix is retained on a No. 10 screen(about 6 to 10 minutes). The mix is then delumped in a laboratory sizedvertical cake finisher until the mix passes through a No. 10 screen(sieve opening of about 2.00 mm.).

1,000 Grams of each fraction is then separately transferred to a largemixing bowl for granulation. About 90 g. of room temperature (apx. 65°F., 18° C.) water is slowly added by a pipette to the bowl containing afraction at a rate of roughly about 20 g./minute while stirring thefraction with moderate agitation to evenly wet the mix. The granules soprepared are dried at 120° F. (40° C.) for about 6 hours. The moisturecontent is then about 3%.

The layer cake fraction granules are then screened. A sieve screenfraction (about 60% of the granules) having the following analysis isselected:

    ______________________________________                                        Through No. 10  100%                                                          On No. 14       100%                                                          ______________________________________                                    

The over and undersized granules are then reworked by grinding to passthrough a No. 50 screen and then repeating the granulation step aboveuntil having the desired sieve screen analysis.

The layer cake fraction granules so prepared are additionally found tohave a bulk porosity of 0.58, a density of about 0.56 g./cc. and aninitial rate of moisture absorption of about 0.065 g./g.s.

Similarly, the pudding fraction granules are screened and/or reworkeduntil the following analysis is obtained:

    ______________________________________                                        Through No. 6   100%                                                          On No. 7        100%                                                          ______________________________________                                    

The pudding fraction granules so prepared are additionally characterizedby a bullk porosity of 0.62, a density of about 0.68 g./cc., and aninitial rate of moisture absorption of about 0.66.

About 635 g. of the granules so prepared (one part pudding fraction tofour parts cake mix fraction) are added to a sized baking pan as inExample I. 350 Grams of water and 7.3 g. of skim milk (0.5 butterfat)are added to the mix. The mixture is then directly placed in an oven andbaked at 350° F. (177° C.) for 25 minutes to form a finished baked layercake.

A layer cake of substantially similar character is prepared when aboutone half of the granules of the present example are substituted with anequivalent amount of the granules of Example I.

What is claimed is:
 1. A dry mix for cakes which requires no mixing oraeration prior to baking and which forms after baking a discontinuouspudding phase, in the finished baked cake comprising:A. from about 70%to 90% by weight of the dry mix of a cake component comprising flour,sugar, leavening and flavor in the form of granules, said granuleshaving1. a particle size of from about 0.9 to 3.0 mm.,
 2. a bulkporosity of from about 0.55 to 0.64,
 3. a density of from about 0.45 to0.7 g./cc.,
 4. an initial rate of moisture absorption of from about0.055 to 0.075 g. of water per gram of layer cake component per second,and
 5. a moisture content of less than about 5% based on said cakecomponent, and; B. from about 10% to 30% by weight of the dry mix of apudding component comprising sugar, flavoring and pregelatinized starchin the form of granules having
 1. a particle size of from about 2.8 to3.4 mm.,2. a bulk porosity of from about 0.50 to 0.65,
 3. a density offrom about 0.5 to 0.7 g./cc.,
 4. an initial rate of moisture absorptionof from about 0.060 to 0.080 g. of water per gram of pudding componentper second, and
 5. a moisture content of less than about 5% based onsaid pudding component.
 2. The dry mix of claim 1 wherein the cakecomponent additionally comprises shortening and an emulsifier.
 3. Thedry mix of claim 2 wherein the cake component granules have:a. aparticle size of from about 1.4 to 2.0 mm.; b. a bulk porosity of fromabout 0.58 to 0.62; c. a density of from about 0.50 to 0.60 g./cc.; d.an initial rate of moisture absorption of from about 0.055 to 0.060g./g.s.; and e. a moisture content of less than about 4%.
 4. The dry mixof claim 3 wherein the cake component comprises about 75% to 80% byweight and about 20% to 25% by weight of the pudding component.
 5. Thedry mix of claim 4 wherein the pudding component granules have:a bulkporosity of from about 0.50 to 0.60; a density of from about 0.5 to 0.65g./cc.; an initial rate of moisture absorption of from about 0.065 to0.075 g./g.s; and a moisture content of less than about 4%.
 6. The drymix of claim 5 wherein the cake component granules have a moisturecontent of less than about 3%.
 7. The dry mix of claim 6 wherein thepudding component granules have a moisture content of less than about3%.
 8. The dry mix of claim 7 wherein the pregelatinized starch is awaxy maize starch and wherein the pudding fraction additionallycomprises from about 0.25% to 1.0% of the pudding fraction of a coldwater soluble gum and from about 0.005% to 0.015% of the puddingfraction of alpha-amylase.
 9. The dry mix mix of 8 wherein the cakecomponent mixture of a first fraction of granules having a first colorand a second fraction of granules having a second color.
 10. The dry mixof claim 9 wherein the pudding component granules comprise a mixture ofa first fraction of granules having a first color and a second fractionof granules having a second color.
 11. The dry mix of claim 10 whereinthe first cake component fraction has a first flavor and the second cakecomponent fraction has a second flavor.
 12. The dry mix of claim 11wherein the first pudding component fraction has a first flavor and thesecond pudding component fraction has a second flavor.
 13. The dry mixof claim 12 additionally comprising from about 1% to 10% by weight ofadjuvant particulate materials.
 14. A method for preparing a finishedcake having after baking a discontinuous pudding phase in the finishedbaked cake consisting essentially of the steps of:A. providing a dry mixfor cakes, said dry mix comprisingI. from about 70% to 90% by weight ofthe dry mix of a cake component comprising flour, sugar, leavening andflavor in the form of granules, said granules havinga. a particle sizeof from about 0.9 to 3.0 mm.; b. a bulk porosity of from about 0.55 to0.64; c. a density of from about 0.45 to 0.7 g./cc. d. an initial rateof moisture absorption of from about 0.055 to 0.075 g. of water per gramof cake component per second; and e. a moisture content of less thanabout 5% based on said cake component, and; II. from about 10% to 30% byweight of the dry mix of a pudding component comprising sugar, flavoringand pregelatinized starch in the form of granules havinga. a particlesize of from about 2.8 to 3.4 mm., b. a bulk porosity of from about 0.50to 0.65, c. a density of from about 0.5 to 0.7 g./cc., d. an initialrate of moisture absorption of from about 0.060 to 0.080 g. of water pergram of pudding component per second, and e. moisture content of lessthan about 5% based on said pudding component; B. hydrating at the sametime both the cake component and pudding component granules in theabsence of agitation by combining with sufficient moisture containingliquids to yield a moisture content of from about 35% to 45%; and,thereafter C. baking at from about 350° F. to 450° F. for from about 25to 45 minutes to yield a baked cake having a discontinuous puddingphase.
 15. The method of claim 14 wherein the cake componentadditionally comprises shortening and an emulsifier.
 16. The method ofclaim 15 wherein the cake component granules have:a. a particle size offrom about 1.4 to 2.0 mm.; b. a bulk porosity of from about 0.58 to0.62; c. a density of from about 0.50 to 0.60 g./cc.; d. an initial rateof moisture absorption of from about 0.055 to 0.060 g./g.s.; and e. amoisture content of less than about 4%.
 17. The method of claim 16wherein the pudding component granules have:a bulk porosity of fromabout 0.50 to 0.60; a density of from about 0.5 to 0.65 g./cc.; aninitial rate of moisture absorption of from about 0.065 to 0.075g./g.s.; and a moisture content of less than about 4%,and wherein thepregelatinized starch is a waxy maize starch and wherein the puddingfraction additionally comprises from about 0.25% to 1.0% of the puddingfraction of a cold water soluble gum and from about 0.005% to 0.015% ofthe pudding fraction of alpha-amylase.
 18. The method of claim 16wherein the cake component comprises about 75% to 80% by weight of thedry mix and about 20% to 25% by weight of the pudding component.
 19. Themethod of claim 17 wherein the cake mix component granules comprise amixture of a plurality of fractions, each fraction having adistinguishing color.
 20. The method of claim 19 wherein the puddingcomponent granules comprise a mixture of a plurality of fractions, eachfraction having a distinguishing color.
 21. The method of claim 20wherein each fraction has a distinguishing second flavor.
 22. The methodof claim 21 additionally comprising the step of arranging the granulefractions into a pattern.
 23. The method of claim 21 additionallycomprising the step of arranging the granule fractions in a randomarray.